Method and apparatus for integral modular masonry flashing

ABSTRACT

A masonry wall includes a masonry foundation, a flashing unit disposed on the masonry foundation, a masonry weep structure, a mortar bed and at least one layer of masonry units disposed upon the mortar bed. A gap defined between the back surface of the masonry unit and the back edge is sufficient to allow water that has seeped through a plurality of masonry units to downwardly toward the platform. A mesh masonry weep structure is disposed on the platform of the flashing unit to allow drainage of water that has seeped behind the wall. A modular flashing unit and template system facilitates building a masonry foundation and quick application of flashing.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to masonry and, more specifically, to athru-wall masonry flashing system.

2. Description of the Prior Art

Typical masonry veneer walls are made by laying a plurality of bricks(or other masonry units, such as stones) in an ordered arrangement. Witha veneer wall, the structural support for the wall is typically a woodor steel frame and the masonry veneer functions aesthetically.

Typically, rainwater is absorbed through masonry veneer in a very shortamount of time. In such a case, a mechanism must be in place to preventthe structural components of the wall and other building assemblies andcomponents from becoming wet. This is typically done by employing thruwall flashing and weep structures. Thru wall flashing is a sheetstructure placed at the bottom regions of a masonry veneer, atintersections and terminations, providing moisture barrier protectionthat allows water to collect and travel in a gap between a verticalportion of the thru wall flashing and the rear surface of the veneer.Water is allowed to drain out of the veneer through the weep structure,which is typically a plastic tube, wicking rope or other type of weep,embedded in the mortar at the bottom of the veneer and on top of thethru wall flashing platform.

Frequently, the masonry veneer must interface with a structure. Forexample, an angled roof may intersect with the masonry veneer of a wall.In such an intersection, a stair-stepped structure of masonry and thruwall flashing is built up by the mason. Once the veneer is complete, aroofer applies counter flashing to the part of the thru wall flashingextending beyond the outer surface of the veneer. The counter flashinginterfaces the veneer with the roof line.

Existing thru wall flashing units are typically made at the job sitefrom sheet metal by masons or sheet metal fabricators. Doing so can betime consuming and costly. The additional step of applying counterflashing adds to the time consumed and the cost.

Also, existing weep structures tend to get clogged with mortar droppingsgenerated by masons. If the weep structures get clogged, then drainagethrough the veneer and cavity wall ventilation is hampered, therebyincreasing the likelihood of moisture-related problems in the framestructure of the wall assemblies and components.

Therefore, there is a need for a flashing system that is relativelyinexpensive, reliable and easy to use.

There is also a need for a flashing system that incorporates both thruwall flashing and counter flashing in a single unit.

There is also a need for a weep structure that resists clogging.

SUMMARY OF THE INVENTION

The disadvantages of the prior art are overcome by the present inventionwhich, in one aspect, is a masonry wall that includes a masonryfoundation, a flashing unit disposed on the masonry foundation, amasonry weep structure, a mortar bed and at least one layer of masonryunits disposed upon the mortar bed. The masonry flashing unit includes aplatform having a front edge and an opposite back edge. The masonryflashing unit has a width between the front edge and the back edge sothat when a masonry unit is disposed on the platform with the frontsurface substantially flush with the front edge, a gap of predeterminedwidth is defined between the back surface of the masonry unit and theback edge. The predetermined width is sufficient to allow water that hasseeped through a plurality of masonry units to downwardly toward theplatform. A back vertical wall, having a top edge, extends upwardly fromthe back edge of the platform The back vertical wall has a height sothat the top edge extends by a predetermined amount beyond the topsurface of a brick of a plurality of masonry units placed on theplatform. A front vertical wall depends downwardly from the front edgeof the platform. A masonry weep structure is disposed on the platform ofthe flashing unit. The masonry weep structure includes a first elongatedmesh strip and a first plurality of spaced-apart mesh fingers extendingfrom the elongated mesh strip. Each finger extends from the elongatedmesh strip at a distance at least equal to a width of a masonry unit.The mesh strip and the mesh fingers are made of a mesh material thatallows water to pass therethrough and that is stable in the presence ofmortar. The mesh fingers terminate in a front surface that is inalignment with the front edge of the platform. The mortar bed isdisposed on the platform of the flashing unit so as to fill in a spacebetween the spaced-apart mesh fingers. The masonry units are disposedupon the mortar bed and the spaced-apart mesh fingers. The layer ofmasonry units has a back surface that is spaced-apart from the backvertical wall of the flashing unit by a predetermined distancesufficient to allow water that has seeped through the masonry units toflow downwardly to the first elongated mesh strip and through thespaced-apart mesh fingers.

In another aspect, the invention is a masonry flashing unit for use witha plurality masonry units wherein each masonry unit has a front surface,an opposite back surface, a bottom surface and an opposite top surface.The masonry flashing unit includes a platform, a back vertical wall anda front vertical wall. The platform has a front edge and an oppositeback edge. The back vertical wall has a top edge and extends upwardlyfrom the back edge of the platform. The back vertical wall has a heightso that the top edge extends by a predetermined amount beyond the topsurface of a masonry unit of the plurality of masonry units placed onthe platform. The front vertical wall depends downwardly from the frontedge of the platform. The platform has a width between the front edgeand the back edge so that when a masonry unit of the plurality ofmasonry units is disposed on the platform with the front surfacesubstantially flush with the front edge, a gap of predetermined width isdefined between the back surface of the masonry unit and the backvertical wall. The predetermined width is sufficient to allow water thathas seeped through the plurality of masonry units to run down the backvertical wall.

In another aspect, the invention is a modular flashing unit for use witha plurality masonry units in which each masonry unit has a frontsurface, an opposite back surface, a bottom surface and an opposite topsurface. The modular flashing unit includes a stepped member, a frontvertical wall and a back vertical wall. The stepped member includes atleast a first latitudinal platform and a second latitudinal platform.The second latitudinal platform is not coplanar with the firstlatitudinal platform. Each of the first latitudinal platform and thesecond latitudinal platform has a front edge, an opposite back edge, afirst side edge and an opposite second side edge. The stepped memberalso includes at least one longitudinal wall connecting the first sideedge of the first latitudinal platform to the second side edge of thesecond latitudinal platform. The longitudinal wall includes a front edgeand an opposite back edge. The stepped member has a width between thefirst latitudinal platform and the second latitudinal platform that iswider than a masonry unit of the plurality of masonry units by apredetermined amount. The front vertical wall has a stepped edgeconnected to the front edge of the first latitudinal platform, the frontedge of the second latitudinal platform and the front edge of thelongitudinal wall. The back vertical wall has a stepped edge that isconnected to the back edge of the first latitudinal platform, the backedge of the second latitudinal platform and the back edge of thelongitudinal wall.

In another aspect, the invention is a masonry weep system that includesa mesh finger, having a first side, an opposite second side, a front endand an opposite back end. The mesh finger is made of a mesh materialthat allows water to pass therethrough and that is stable in thepresence of mortar. The mesh finger placed on a masonry foundation.Mortar is placed on the masonry foundation and is disposed about thefirst side and the second side of the mesh finger and does not cover theback end or the front end.

In another aspect, the invention is a masonry weep structure thatincludes a first elongated mesh strip and a first plurality ofspaced-apart mesh fingers that extend from the elongated mesh strip.Each finger extends from the elongated mesh strip at a distance at leastequal to a width of a masonry unit. The mesh strip and the mesh fingersare made of a mesh material that allows water to pass therethrough andthat is stable in the presence of mortar.

In yet another aspect, the invention is a method of making a modularflashing system for a user to employ with a masonry foundation.Dimensions corresponding to the masonry foundation are received. Amodular flashing system that is sized to fit the masonry foundation ismade based on the dimensions. A template that has an edge thatcorresponds to an edge of the masonry foundation is made. The templateis delivered to the user so that when the user builds the masonryfoundation according to the template, the modular flashing system willfit the masonry foundation.

These and other aspects of the invention will become apparent from thefollowing description of the preferred embodiments taken in conjunctionwith the following drawings. As would be obvious to one skilled in theart, many variations and modifications of the invention may be effectedwithout departing from the spirit and scope of the novel concepts of thedisclosure.

BRIEF DESCRIPTION OF THE FIGURES OF THE DRAWINGS

FIG. 1A is a top perspective view of one embodiment of a flashing unit.

FIG. 1B is a front elevational view of the embodiment shown in FIG. 1A.

FIG. 1C is a cross sectional view of the embodiment shown in FIG. 1B,taken along line 1C-1C.

FIG. 2A is a top perspective view of a second embodiment of a flashingunit.

FIG. 2B is a front elevational view of the embodiment shown in FIG. 1B.

FIG. 2C is a front elevational view of a third embodiment of a flashingunit.

FIG. 2D is a front elevational view of several flashing units, as shownin FIG. 2C, used together.

FIG. 3A is a plan view of one embodiment of a weep structure.

FIG. 3B is a cross-sectional view of mesh used in a weep structure.

FIG. 3C is a plan view of a weep structure, as shown in FIG. 3A, usedwith mortar.

FIG. 3D is a plan view of a weep structure strip.

FIG. 4A is a cross-sectional view of a flashing unit, a weep structureand masonry units used together to form a masonry wall.

FIG. 4B is a front elevational view of the wall shown in FIG. 4A.

FIG. 5 is a plan view of a second embodiment of a weep structure.

FIG. 6A is a top perspective view of a modular flashing system.

FIG. 6B is a front elevational view of a stepped member of a modularflashing unit.

FIG. 6C is a front elevational view of a flashing template.

FIG. 6D is a front elevational view of a flashing template applied to amasonry foundation.

FIG. 6E is a front elevational view of a masonry foundation madeaccording to the template shown in FIG. 6D.

FIG. 6F is a front elevational view of the masonry foundation shown inFIG. 6E, with the stepped member shown in FIG. 6B applied thereto.

DETAILED DESCRIPTION OF THE INVENTION

A preferred embodiment of the invention is now described in detail.Referring to the drawings, like numbers indicate like parts throughoutthe views. As used in the description herein and throughout the claims,the following terms take the meanings explicitly associated herein,unless the context clearly dictates otherwise: the meaning of “a,” “an,”and “the” includes plural reference, the meaning of “in” includes “in”and “on.” “Masonry unit” includes any unit of solid masonry material,including a brick, a concrete block, a ceramic block, a glass block, apiece of stone, or any unit of any other type of material that is usedto make a masonry wall. “Mortar” includes cement, grout and anysubstance used to bind masonry units.

As shown in FIGS. 1A-1C, one embodiment of the invention is a thru-wallmasonry flashing unit 100 that includes a platform 110 having a frontedge 112, an opposite back edge 114 and a first side edge 116. A backvertical wall 120, having a top edge 122, extends upwardly from the backedge 114 of the platform 110. The back vertical wall 120 has a height sothat the top edge 122 extends by a predetermined amount (typically twoinches) beyond the top surface 154 of a masonry unit 150 (such as abrick) of the plurality of masonry units 150 placed on the platform 110.A front vertical wall 130 depends downwardly from the front edge 112 ofthe platform 110. The width of the platform 110 between the front edge112 and the back edge 114 is sufficient so that a gap 126 is definedbetween the back vertical wall 120 and the back surface 152 of masonryunits 150 placed on the platform 110 so that the front surface 156 ofthe masonry units 150 are aligned with the front vertical wall 130. Thegap 126 is wide enough (typically one inch) to allow water that hasseeped through the plurality of masonry units 150 to run down the backvertical wall 120 to the platform 110. The front vertical wall 130 has abottom edge 132 that may be either flat or at an angle a, depending onthe location where the masonry flashing unit 100 is being used. Theplatform 110, the front vertical wall 130 and the back vertical wall 120may be formed from a single piece of a material, such as sheet metal(e.g., copper, aluminum, or galvanized steel) or plastic (e.g., PVC,HDPE, composites, laminates). If a sheet thermoplastic is used, theembodiments of the flashing units shown herein can be made throughvacuum forming.

As shown in FIGS. 2A-2B, a vertical side wall 210, having a top edge212, can extend upwardly from the first side edge 116. As shown in FIG.2C, a lip 214 can be formed in the vertical side wall 210. The lip 214can be manufactured at a manufacturing facility, or it can be formed atthe job site using a pair of metal shears and a pair of pliers. As shownin FIG. 2D, if the height of the vertical side wall 210 of masonryflashing units 100 is chosen correctly, they can be stacked so thattheir bottom edges 132 are in substantial alignment. This is a usefulfeature when it is desirable for the bottom edges 132 are to follow aroof line. By having the platforms 110 overlap the vertical side walls210, water flowing through the masonry units into the flashing units 100will not leak out of the flashing units 100 into the frame structureabout which the masonry is being applied.

A weep structure may be used with the flashing units 100 disclosedherein. While a conventional weep structure, such as a plastic tube, maybe used to drain water from the gap 126, a mesh-type weep structure 300,as shown in FIG. 3A, offers several advantages. Such a weep structure300 includes a first elongated mesh strip 310 and a first plurality ofspaced apart mesh fingers 320, each extending from the elongated meshstrip 310. Each finger 320 is at least as long as a masonry unit iswide. As shown in FIG. 3B, the mesh strip 310 and the mesh fingers 320are made of a mesh material 302, shown in FIG. 3B, that allows water topass therethrough and that is stable in the presence of mortar. The meshfingers 320 terminate in a front surface 322. Examples of a suitablemesh material 302 include a nonwoven thermoplastic mesh (such as apolyester fiber mesh). One example of a suitable mesh is COBRA® RIDGEVENT, available from Cobra Ventilation Co., Inc., 1361 Alps Road, Wayne,N.J. 07470-3689. As shown in FIG. 3C, the weep structure 300 may be usedwith a mortar bed 312, to allow water to drain out of a masonrystructure. As shown in FIG. 3D, the mesh-type weep structure 300, may besold as a mesh strip that includes tear lines 318 that allow thecontractor to separate two cross-positioned weep structures 300 bytearing them apart. Additional pieces 330 of mesh may also be includedin the strip. Such pieces 330 of mesh may be used for individual weeps.As shown in FIG. 6, a shaped mesh weep structure 600 may be made inwhich the fingers 620 are shaped for esthetic or branding purposes.

As shown in FIGS. 4A and 4B, a masonry wall 400 may be made according toone embodiment of the invention. The wall 400 includes a foundation 410,typically made of several layers masonry units 150 topped with a mortarbed 412. Before hardening of the mortar bed 412, a flashing unit 100 isplaced on the mortar bed 412. The weep structure 300 is then placed onthe platform 110 of the flashing unit 100 and a layer of mortar 312 isapplied between the fingers 320. Upon this combination of the weepstructure 300 and the mortar 312 is placed the masonry units 150 thatmake up the wall 400. A bead of calk 402 may be applied to the bottomedge 132 of the front vertical wall 130 to provide a more estheticappearance.

One embodiment of a modular flashing system 700 is shown in FIGS. 6A-6C.The modular flashing system 700 includes a modular flashing unit 710 anda corresponding planar template 760. The modular flashing unit 710includes a stepped member 711, a front vertical wall 740, and a backvertical wall 750. The stepped member 711 includes a plurality oflatitudinal platforms 712 connected by longitudinal walls 730 to form astepped shape. The stepped member 711 has a front edge 732, an oppositeback edge 734, a first side edge 716 and an opposite second side edge718. The front vertical wall 740 has a stepped edge 742 connected to thefront edge 714 of the stepped member 711. The front vertical wall 740also includes a bottom edge 742. The back vertical wall 750 has astepped edge 752 connected to the back edge 720 of the stepped member711.

As shown in FIGS. 7A and 7C, the planar template 760 has dimensions thatcorrespond to the front vertical wall 740 of the modular flashing unit710. The planar template 760 has a top stepped edge 764 and a bottomangled edge 762. As shown in FIG. 7D, the planar template 760 is used asa template to build a masonry foundation 770. The masonry foundation 770is the foundation upon which the modular flashing unit 710 will beinstalled.

As shown in FIGS. 7E and 7F, once the masonry foundation 770 iscomplete, a mortar bed 772 is placed on the masonry foundation 770 andthe modular flashing unit 710 is placed on the mortar bed 772 before itsets. This ensures a good fit for the modular flashing unit 710 andensures that it is well supported by the masonry foundation 770.

The modular flashing unit 710 could be made in one of several ways. Forexample, it could be made from sheet metal using conventionalmetalworking techniques. Similarly, it could be made from sheet plasticusing conventional plastic fabrication techniques, including vacuumforming The planar template 760 could be made from one of many sheetmaterials, including metal, plastic or even sturdy cardboard.

In one method of making the modular flashing unit 710, a builder orarchitect sends the dimensions for the masonry foundation 770 to afabrication facility. The fabrication facility would employ aconventional computer-aided design and manufacturing (CAD/CAM) system todesign the modular flashing unit 710 and the planar template 760, usingpredefined criteria, based on the dimensions. The CAD/CAM system wouldcontrol the necessary cutting tools (such as a LASER cutting tool) tocut out the necessary parts.

In one embodiment, a sheet cutting facility or a stair manufacturer,could make two copies of the planar template 760, each of which ismarked with a unique identifier that corresponds to the specific usespecified by the builder. One of the dual twin templates is sent to themason; thereby allowing the building of the masonry foundation 770 tocommence, and the other is sent to a fabrication facility for use in thefabrication of the modular flashing unit 710. Making the masonryfoundation 770 in tandem with the planar template 760 allows forefficient workflow.

The above described embodiments are given as illustrative examples only.It will be readily appreciated that many deviations may be made from thespecific embodiments disclosed in this specification without departingfrom the invention. Accordingly, the scope of the invention is to bedetermined by the claims below rather than being limited to thespecifically described embodiments above.

1. A masonry wall, comprising: a. a foundation; b. a flashing unitdisposed on the foundation, the masonry flashing unit comprising: i. aplatform having a front edge and an opposite back edge and having awidth between the front edge and the back edge so that when a masonryunit is disposed on the platform with a front surface substantiallyflush with the front edge, a gap is defined between the back surface ofthe masonry unit and the back edge; ii. a back vertical wall, having atop edge, extending upwardly from the back edge of the platform, theback vertical wall having a height so that the top edge extends by apredetermined amount beyond the top surface of a masonry unit of aplurality of masonry units placed on the platform; and iii. a frontvertical wall depending downwardly from the front edge of the platform;c. a masonry weep structure placed on the platform of the flashing unit,the masonry weep structure including: i. a first elongated mesh strip;and ii. a first plurality of spaced-apart mesh fingers extending fromthe elongated mesh strip, each finger extending from the elongated meshstrip at a distance at least equal to a width of a masonry unit, themesh strip and the mesh fingers made of a mesh material that allowswater to pass therethrough and that is stable in the presence of mortar,the mesh fingers terminating in a front surface that is in alignmentwith the front edge of the platform; d. a mortar bed disposed on theplatform of the flashing unit so as to fill in a space between thespaced-apart mesh fingers; and at least one layer of masonry unitsdisposed upon the mortar bed and the spaced-apart mesh fingers, thelayer having a back surface that is spaced-apart from the back verticalwall of the flashing unit by a predetermined distance sufficient toallow water that has seeped through the masonry units to flow down tofirst elongated mesh strip and through the spaced-apart mesh fingers. 2.A masonry flashing unit for use with a plurality masonry units, eachmasonry unit having a front surface, an opposite back surface, a bottomsurface and an opposite top surface, the masonry flashing unitcomprising: a. a platform having a front edge and an opposite back edge;b. a back vertical wall, having a top edge, extending upwardly from theback edge of the platform, the back vertical wall having a height sothat the top edge extends by a predetermined amount beyond the topsurface of a masonry unit of the plurality of masonry units placed onthe platform; and c. a front vertical wall depending downwardly from thefront edge of the platform, the platform having a width between thefront edge and the back edge so that when a masonry unit of theplurality of masonry units is disposed on the platform with the frontsurface substantially flush with the front edge, a gap of predeterminedwidth is defined between the back surface of the masonry unit and theback vertical wall, the predetermined width being sufficient to allowwater that has seeped through the plurality of masonry units to flowdownwardly to the platform.
 3. The masonry flashing unit of claim 2,wherein the platform, the front vertical wall and the back vertical wallare formed from a single piece of a material.
 4. The masonry flashingunit of claim 3, wherein the material is selected from a groupconsisting essentially of: a metal and a plastic.
 5. The masonryflashing unit of claim 2, wherein the front vertical wall defines abottom edge, wherein the bottom edge is at an angle that is transverseto the platform.
 6. The masonry flashing unit of claim 5, wherein theplatform has a side edge, the masonry flashing unit further comprising avertical side wall, having a top edge, extending upwardly from the sideedge.
 7. The masonry flashing unit of claim 6, further comprising a lipextending outwardly from the top edge of the vertical side wall.
 8. Themasonry flashing unit of claim 6, wherein the vertical side wall has aheight so that when a first masonry flashing unit is placed on top of asecond masonry flashing unit so that the platform of the second masonryflashing unit rests on the top edge of the vertical side wall of thefirst masonry flashing unit and so that the platform of the secondmodular flashing unit overlaps the vertical sidewall of the firstmodular flashing unit, the bottom edge of the front vertical wall of thefirst modular flashing unit is in substantial alignment with the bottomedge of the front vertical wall of the second modular flashing unit. 9.A modular flashing unit for use with a plurality masonry units, eachmasonry unit having a front surface, an opposite back surface, a bottomsurface and an opposite top surface, the modular flashing unitcomprising a. a stepped member including at least a first latitudinalplatform and a second latitudinal platform, the second latitudinalplatform being not coplanar with the first latitudinal platform, each ofthe first latitudinal platform and the second latitudinal platformhaving a front edge, an opposite back edge, a first side edge and anopposite second side edge, the stepped member also including at leastone longitudinal wall connecting the first side edge of the firstlatitudinal platform to the second side edge of the second latitudinalplatform, the longitudinal wall including a front edge and an oppositeback edge, the stepped member having a width between the firstlatitudinal platform and the second latitudinal platform that is widerthan a masonry unit of the plurality of masonry units by a predeterminedamount; b. a front vertical wall having a stepped edge connected to thefront edge of the first latitudinal platform, the front edge of thesecond latitudinal platform and the front edge of the longitudinal wall;and c. a back vertical wall having a stepped edge connected to the backedge of the first latitudinal platform, the back edge of the secondlatitudinal platform and the back edge of the longitudinal wall.
 10. Themodular flashing unit of claim 9, further comprising a planar templatethat has dimensions corresponding to a masonry foundation upon which themodular flashing unit is to be installed, so that when the masonryfoundation is made according to the template, the modular flashing unitwill fit on the masonry foundation.
 11. The modular flashing unit ofclaim 9, wherein the stepped member, the front vertical wall, and theback vertical wall are all made from a unitary sheet of a material. 12.The modular flashing unit of claim 11, wherein the material comprises aplastic.
 13. The modular flashing unit of claim 12, wherein the plastichas been vacuum-formed.
 14. A masonry weep system, comprising: a. a meshfinger, having a first side, an opposite second side, a front end and anopposite back end, the mesh finger made of a mesh material that allowswater to pass therethrough and that is stable in the presence of mortar,the mesh finger placed on a masonry foundation; and b. mortar placed onthe masonry foundation and disposed about the first side and the secondside of the mesh finger and not covering the back end or the front end.15. A masonry weep structure, comprising: a. a first elongated meshstrip; and b. a first plurality of spaced-apart mesh fingers extendingfrom the elongated mesh strip, each finger extending from the elongatedmesh strip at a distance at least equal to a width of a masonry unit,the mesh strip and the mesh fingers made of a mesh material that allowswater to pass therethrough and that is stable in the presence of mortar.16. The masonry weep structure of claim 15, wherein the mesh strip andthe mesh fingers comprise a non-woven plastic mesh.
 17. The masonry weepstructure of claim 15, further comprising: a. a second elongated meshstrip; and b. a second plurality of spaced-apart mesh fingers extendingfrom the elongated mesh strip, each finger extending from the elongatedmesh strip at a distance at least equal to a width of a masonry unit,the second elongated strip and the second plurality of spaced-apart meshfingers in opposed engagement with the first elongated mesh strip andthe first plurality of spaced-apart mesh fingers, so as to form a singlebelt of mesh with division to facilitate separation of the firstelongated mesh strip and the first plurality of spaced apart meshfingers from the second elongated mesh strip and the second plurality ofspaced-apart mesh fingers.
 18. A method of making a modular flashingsystem for a user to employ with a masonry foundation, comprising thesteps of: a. receiving dimensions corresponding to the masonryfoundation; b. making a modular flashing system that is sized to fit themasonry foundation, based on the dimensions; c. making a template thathas an edge that corresponds to an edge of the masonry foundation; andd. delivering the template to the user so that when the user builds themasonry foundation according to the template, the modular flashingsystem will fit the masonry foundation.